Convertible packaging

0001This application is a divisional of U.S. patent application Ser. No. 12/098,325, filed Apr. 4, 2008, pending, the entire content of which is hereby incorporated by reference in this application.

BACKGROUND

0002Products are typically shipped in packaging assemblies such as boxes or other types of containers. The containers help facilitate shipment of the products, for example by protecting the products from damage. Products are shipped in containers in an assembled manner, or the products are shipped in an unassembled manner and the product is assembled after removal from the packaging assembly. In addition, some packaging assemblies include protective inserts. Protective inserts are placed between or around portions of the product. Such protective inserts protect the product from damage during shipment by helping to prevent portions of the product from damaging one another. Other protective inserts are configured to reinforce the container in addition to protecting the product.

SUMMARY

0003Some aspects of the present invention relate to a shipping system including an article of furniture and a packaging assembly. The packaging assembly includes a container and a protective insert. The container houses the article of furniture. The protective insert is disposed within the container and is positioned to help protect the article of furniture from damage. The protective insert has at least one convertible portion that is adapted to be removed from a surrounding portion of the protective insert, adapted to transition between a first configuration and a second configuration, and adapted to form at least a portion of an accessory product for the article of furniture when the convertible portion is in the second configuration.

0004While some aspects of the invention have been described above, still other aspects of the present invention will become apparent to those skilled in the art from the following detailed description. Accordingly, the summary is intended to be generally indicative of some aspects of the invention, but not restrictive in nature.

BRIEF DESCRIPTION OF THE DRAWINGS

0005<figref idref="DRAWINGS">FIG. 1</figref> is a primary product with accessory products, according to some embodiments;

0006<figref idref="DRAWINGS">FIG. 2</figref> shows the primary product of <figref idref="DRAWINGS">FIG. 1</figref> packaged in a box;

0007<figref idref="DRAWINGS">FIG. 3</figref> shows a protective insert with convertible portions, according to some embodiments;

0008<figref idref="DRAWINGS">FIG. 4</figref> shows another protective insert with convertible portions, according to some embodiments;

0009<figref idref="DRAWINGS">FIG. 5</figref> shows a convertible portion of a packaging assembly converted into the form of a portfolio, according to some embodiments;

0010<figref idref="DRAWINGS">FIG. 6</figref> shows a convertible portion of a packaging assembly converted into the form of a pencil holder, according to some embodiments;

0011<figref idref="DRAWINGS">FIG. 7</figref> shows a convertible portion of a packaging assembly converted into the form of a coaster, according to some embodiments;

0012<figref idref="DRAWINGS">FIG. 8</figref> shows a convertible portion of a packaging assembly converted into the form of a holder for a storage media, according to some embodiments;

0013<figref idref="DRAWINGS">FIG. 9</figref> shows a convertible portion of a packaging assembly converted into the form of a picture frame, according to some embodiments;

0014<figref idref="DRAWINGS">FIG. 10</figref> shows a convertible portion of a packaging assembly converted into the form of a rack, according to some embodiments;

0015<figref idref="DRAWINGS">FIG. 11</figref> shows a convertible portion of a packaging assembly converted into the form of an alternative pencil holder, according to some embodiments;

0016<figref idref="DRAWINGS">FIG. 12</figref> shows a convertible portion of a packaging assembly converted into the form of a cup holder, according to some embodiments;

0017<figref idref="DRAWINGS">FIG. 13</figref> shows a convertible portion of a packaging assembly converted into the form of a decorative pencil holder, according to some embodiments;

0018<figref idref="DRAWINGS">FIG. 14</figref> shows a convertible portion of a packaging assembly converted into the form of an inbox, according to some embodiments;

0019<figref idref="DRAWINGS">FIG. 15</figref> shows a convertible portion of a packaging assembly converted into the form of a side view of an electronic device holder, according to some embodiments;

0020<figref idref="DRAWINGS">FIG. 16</figref> shows a convertible portion of a packaging assembly converted into the form of an electronic device holder, according to some embodiments; and

0021<figref idref="DRAWINGS">FIG. 17</figref> shows a picture frame with a convertible matte disposed in the frame, according to some embodiments.

0022While the invention is amenable to various modifications and alternative forms, some embodiments have been shown by way of example in the drawings and are described in detail below. As referenced above, the intention, however, is not to limit the invention by those examples. On the contrary, the invention is intended to cover all modifications, equivalents, and alternatives.

DETAILED DESCRIPTION

0023In general terms, some aspects of the invention relate to packaging systems where pieces of a primary product, such as an unassembled desk, are packaged in a shipping container, such as a cardboard box. The pieces of the product are shipped with protective inserts (e.g., sheets of packing cardboard) between them. The protective insert(s) are adapted to be formed into accessory products, such as desk accessories. In some embodiments, the protective insert(s) are scored so that a consumer, or other user, is able to punch out accessory blanks and fold or otherwise form them into the accessory products intended for use with the primary product (e.g., a pencil holder to be used with a desk).

0024As will be described in greater detail, the primary product, also described as a retail item or main product, is provided with one or more secondary products via packaging materials used to ship or otherwise house the primary product. As alluded to above, the primary product is optionally an article of furniture, also described as a furniture assembly or a furniture member. During storage and/or shipment, the primary product is at least partially protected by a packaging assembly, which can also be described as a shipping assembly, a shipping module, or a protective packaging. The primary product is optionally disposed within the packaging in an assembled or unassembled state as desired.

0025In some embodiments, the packaging assembly includes an outer container (e.g., a box), which can also be described as outer packaging or a shipping container and one or more protective inserts, which are also described as shipping inserts, packaging inserts, shipping members, or packing/packaging members. The protective inserts are optionally used together with the container to protect the primary product during storage and/or shipment.

0026The packaging assembly has one or more convertible portions, or accessory portions, that are convertible from a first, shipping configuration to a second, accessory configuration. In the first configuration, the convertible portions are configured as a portion of the packaging assembly. In the second configuration, the convertible portions are configured as secondary products, or accessories. The secondary products are for use with the primary product and as such are accessory products for the primary product. The secondary products can also be described as accessory members, accessory products, accessories, appurtenances, or supplementary products. In some embodiments, packaging assemblies that include convertible portions are environmentally friendly or otherwise help reduce waste by making use of portions of the packaging assembly that might otherwise be discarded or inefficiently used.

0027For example, in <figref idref="DRAWINGS">FIG. 1</figref>, a primary product <b>10</b> is shown with a plurality of accessory products <b>20</b>, <b>22</b>, <b>24</b>, <b>26</b>, <b>28</b>. In some embodiments, the primary product <b>10</b> is a desk <b>10</b> having a desk top <b>12</b>, a desk rail <b>14</b> providing support to the desk top <b>12</b>, and desk legs <b>16</b>. The accessory products <b>20</b>, <b>22</b>, <b>24</b>, <b>26</b>, <b>28</b> are optionally a pencil holder <b>20</b>, a coaster <b>22</b>, a picture frame <b>24</b>, a desk organizer <b>26</b> and an inbox/outbox <b>28</b>, respectively, where each of the accessory products is optionally formed from a portion of protective packaging used to house the primary product <b>10</b> for shipping, for example.

0028<figref idref="DRAWINGS">FIG. 2</figref> shows the desk <b>10</b> of <figref idref="DRAWINGS">FIG. 1</figref> disposed in a packaging assembly <b>30</b> including an outer packaging <b>31</b>, such as a box or other container. The outer packaging <b>31</b> includes a top <b>32</b>, a bottom (not shown), ends <b>34</b>, and sides <b>36</b>. The packaging assembly <b>30</b> also optionally includes one or more protective inserts <b>40</b>, <b>41</b>, <b>42</b>. The protective inserts <b>40</b>, <b>41</b>, <b>42</b> interact with other portions of the packaging assembly <b>30</b> such as the outer packaging <b>31</b> to strengthen the outer packaging <b>31</b> and/or to protect the primary product <b>10</b> during storage and/or shipment, for example by separating and cushioning portions of the primary product <b>10</b> from each other.

0029In some embodiments, the top <b>32</b> has two flaps that have an open and a closed configuration (the flaps are shown in <figref idref="DRAWINGS">FIG. 2</figref> in the closed configuration). An optional outer protective insert <b>40</b> is placed between the top <b>32</b> and the primary product <b>10</b>. An outer protective insert <b>41</b> is also optionally disposed between the primary product <b>10</b> and the bottom of the outer packaging <b>31</b>. The outer protective inserts <b>40</b>, <b>41</b> reinforce the top <b>32</b> and bottom, respectively. Together with the outer packaging <b>31</b>, the outer protective inserts <b>40</b>, <b>41</b> also protect the primary product <b>10</b> during shipment. Other outer protective inserts (not shown) are optionally included between the primary product <b>10</b> and one or both of the ends <b>34</b> and/or between the primary product <b>10</b> and one or more of the sides <b>36</b>.

0030As alluded to above, the desk <b>10</b> is optionally disposed in the outer packaging <b>31</b> in an unassembled state, or configuration, as shown in <figref idref="DRAWINGS">FIG. 2</figref>. The legs <b>16</b> are optionally removed from the desk top <b>12</b> with the legs <b>16</b> disposed between the lower outer protective insert <b>41</b> and an inner protective insert <b>42</b>. The desk top <b>12</b> is optionally disposed between the inner protective insert <b>42</b> and the upper outer protective insert <b>40</b>. The inner protective insert <b>42</b> separates the desk top <b>12</b> from the desk legs <b>16</b>, helping to prevent these different portions of the desk <b>10</b> from damaging one another during storage and/or shipment.

0031In some embodiments, the protective inserts <b>40</b>, <b>41</b>, <b>42</b> are in the form of a sheet of packaging material such as cardboard, although a variety of packaging materials are contemplated. Though not specifically shown, additional or alternative protective inserts are also optionally folded or arranged into configurations to surround portions of the primary product <b>10</b> to provide additional protection during storage and/or shipment. In addition, in some embodiments, protective inserts are folded or arranged to form sub-containers and/or divisions within the outer packaging <b>31</b>. These sub-containers or divisions are configured for packaging a portion of the primary product <b>10</b> and/or other items that are shipped with the primary product <b>10</b> (e.g., additional accessory products, directions for assembly, hardware for assembling the primary or accessory products, or others). Although the embodiments described below and shown in the figures include protective inserts in the form of a flat sheet of packing material with convertible portions, any portions of the packaging assembly <b>30</b> optionally comprise one or more convertible portions such as those described below. For example, in some embodiments the outer packaging <b>31</b> comprises any of the convertible portions described herein.

0032In some embodiments, the outer packaging <b>31</b> and the protective inserts <b>40</b>, <b>41</b>, <b>42</b> are made of packaging materials such as cardboard or paperboard. The cardboard is optionally corrugated cardboard, and in some embodiments the weights of the cardboard is from about 150 gsm to about 300 gsm, although other weights are contemplated. In addition, in some embodiments the outer packaging <b>31</b> comprises one weight of cardboard or paperboard (e.g., 300 gsm) while the protective inserts <b>40</b>, <b>41</b>, <b>42</b> comprise a different weight of cardboard or paperboard (e.g., 150 gsm).

0033In some embodiments, the convertible portion or portions of the packaging assembly <b>30</b> are formed by perforating or scoring blanks in the shape of the convertible portion(s) in a portion of the packaging assembly <b>30</b>. The perforation or scoring provides a weakened portion of the packaging assembly <b>30</b> that is then punched out from the surrounding non-convertible portion of the packaging assembly <b>30</b>. In this way, the convertible portion(s) are removed from the surrounding non-convertible portions and is converted into one or more accessory products. The perforation or scoring in the packaging assembly <b>30</b> is shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref> with solid lines and generally correspond to structures of various accessory products.

0034Also, as explained in detail below with respect to <figref idref="DRAWINGS">FIGS. 3-17</figref>, fold lines are provided in the convertible portions of some embodiments. These fold lines are provided by making an impression or indentation along the fold lines of the convertible portions. The fold lines in the convertible portions are shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref> with broken lines and generally correspond to structures of various accessory products.

0035In some embodiments, all or a portion of a convertible portion is printed. For example, one or more of the convertible portions are printed to improve the aesthetics of accessory products that are formed from the one or more convertible portions of a packaging assembly <b>30</b>. In other embodiments, one or more convertible portions are coated, for example with a protective coating, a waterproof coating, a water resistant coating, or with other types of coatings.

0036The packaged primary product shown in <figref idref="DRAWINGS">FIG. 2</figref> also optionally includes other items, such as directions for using and/or assembling the primary product <b>10</b> and accessory products, along with any tools or hardware that are required for assembly or use of the primary product <b>10</b> or accessory products.

0037Shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref> are example embodiments of protective inserts. As mentioned above, the protective inserts <b>45</b>, <b>46</b> are placed in a container in order to protect the primary product <b>10</b> and/or reinforce the container. For example, either or both of the protective inserts <b>45</b>, <b>46</b> are optionally disposed within the outer packaging <b>31</b> as any of protective inserts <b>40</b>, <b>41</b>, <b>42</b> shown in <figref idref="DRAWINGS">FIG. 2</figref>.

0038The protective inserts <b>45</b>, <b>46</b> have convertible portions. For example, protective insert <b>45</b> in <figref idref="DRAWINGS">FIG. 3</figref> has convertible portions <b>47</b>-<b>53</b> and protective insert <b>46</b> in <figref idref="DRAWINGS">FIG. 4</figref> has convertible portions <b>54</b>-<b>59</b>. The convertible portions have a first configuration and a second configuration. In the first configuration, the convertible portions are in a packaging configuration as shown in <figref idref="DRAWINGS">FIGS. 3 and 4</figref>, and are configured to protect the primary product <b>10</b> and/or reinforce the packaging assembly <b>30</b>. In the second configuration, the convertible portions are configured as accessory products for the primary product <b>10</b>.

0039In embodiments where the protective inserts <b>40</b>, <b>41</b>, <b>42</b> comprise corrugate materials, the corrugate material is optionally oriented in a predetermined direction. For example, the corrugate direction is oriented as shown by arrow A in <figref idref="DRAWINGS">FIG. 3</figref> and arrow B in <figref idref="DRAWINGS">FIG. 4</figref>, although other corrugate orientations are possible.

0040Turning to <figref idref="DRAWINGS">FIG. 3</figref>, protective insert <b>45</b> has convertible portions <b>47</b>-<b>53</b>. These convertible portions <b>47</b>-<b>53</b> are each shown in a first configuration. Convertible portion <b>47</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 3</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 5</figref>. In the second configuration, the convertible portion <b>47</b> forms a portfolio <b>60</b> having pockets that are configured to hold papers. The portfolio <b>60</b> has two sides <b>61</b> that are demarcated by two fold lines <b>74</b>. The sides <b>61</b> are folded toward and away from one another along the fold lines <b>74</b> in order to change the portfolio <b>60</b> between an open and a closed configuration. The portfolio <b>60</b> is shown in <figref idref="DRAWINGS">FIG. 5</figref> in an open configuration.

0041In some embodiments, two adjacent fold lines help facilitate folds of greater than 90 degrees. For example, adjacent fold lines <b>74</b> help facilitate the 180 degree fold that is formed between the two sides <b>61</b> when the portfolio is in a closed configuration. It should be noted that, although two adjacent fold lines are shown only for folds of greater than 90 degrees, two or more adjacent fold lines are optionally used to help facilitate any of the folds described herein. In addition, in embodiments where two or more adjacent fold lines are shown, a single fold line is optionally used, for example when the packaging material being used has a relatively high level of flexibility.

0042In addition, each side <b>61</b> of the portfolio <b>60</b> has upper flaps <b>62</b> that each have an inner edge <b>64</b> and lower flaps <b>66</b> that each have an inner edge <b>68</b>. The upper flaps <b>62</b> are demarcated from the sides <b>61</b> along adjacent fold lines <b>72</b>, which help allow the upper flaps <b>62</b> to be folded in toward the center of the portfolio <b>60</b> as shown in <figref idref="DRAWINGS">FIG. 5</figref>. The lower flaps <b>66</b> are demarcated from the sides <b>61</b> along adjacent fold lines <b>70</b>, which help allow the lower flaps <b>66</b> to be folded upward toward the top of the portfolio <b>60</b> as shown in <figref idref="DRAWINGS">FIG. 5</figref>. When the upper flaps <b>62</b> are folded inward and the lower flaps <b>66</b> are folded upward as shown in <figref idref="DRAWINGS">FIG. 5</figref>, the edges <b>64</b>, <b>68</b> are disposed adjacent to, or in some cases touching, one another, forming pockets. The portfolio <b>60</b> also includes notches <b>76</b>. These notches <b>76</b> are formed along the outside and bottom of the sides <b>61</b>. When the flaps <b>62</b>, <b>66</b> are in a folded configuration, an elastic band <b>79</b> is placed across the flaps <b>62</b>, <b>66</b> and through the notches <b>76</b> in order to hold the flaps <b>62</b>, <b>66</b> in the configuration shown in <figref idref="DRAWINGS">FIG. 5</figref>. The notches <b>76</b> keep the elastic bands <b>79</b> in place around the flaps <b>62</b>, <b>66</b> of the portfolio <b>60</b>. The elastic bands <b>79</b> in this embodiment, and in other embodiments described herein, are optionally rubber bands or packing bands or another type of fastener. For example, in some embodiments clips or tape are used in addition to or in place of the elastic bands <b>79</b> to help maintain the portfolio <b>60</b> in the configuration shown in <figref idref="DRAWINGS">FIG. 5</figref>. In addition, fastening means such as adhesive are also contemplated for fastening adjacent portions of an accessory product to one another.

0043Convertible portion <b>48</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 3</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 6</figref>. In the second configuration, the convertible portion <b>48</b> forms a pencil holder <b>20</b>. The pencil holder <b>20</b> has a large opening that accommodates two or more writing utensils. The pencil holder <b>20</b> has a base <b>80</b> (shown in <figref idref="DRAWINGS">FIG. 3</figref>) and four sides <b>82</b>. The sides <b>82</b> are demarcated from the base <b>80</b> by fold lines <b>84</b>, and the sides <b>82</b> each have two edges <b>85</b>. Formed on the edges <b>85</b> are notches <b>86</b>. The sides <b>82</b> are folded upward relative to the base <b>80</b> along the fold lines <b>84</b> in order to form sides of the pencil holder <b>20</b>, as shown in <figref idref="DRAWINGS">FIG. 6</figref>. In some embodiments, elastic bands <b>79</b> are disposed through the notches <b>86</b> and around the sides <b>82</b> of the pencil holder <b>20</b> in order to help maintain the pencil holder <b>20</b> in the second configuration. Further, each pair of adjacent edges <b>85</b> has a tab <b>88</b> on one of the adjacent edges <b>85</b> and a corresponding alignment notch <b>90</b> on the other adjacent edge <b>85</b>. When the sides <b>82</b> are folded upward, forming the pencil holder <b>20</b>, the tabs <b>88</b> fit into the corresponding alignment notch <b>90</b> to help ensure that the adjacent edges <b>85</b> are aligned properly.

0044Convertible portion <b>49</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 3</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 7</figref>. In the second configuration, the convertible portion <b>49</b> forms a coaster <b>22</b>. The convertible portion <b>49</b> has three panels <b>100</b>, <b>102</b>, <b>104</b> (as best shown in <figref idref="DRAWINGS">FIG. 3</figref>). Panel <b>102</b> has a first cut-out <b>106</b> and panel <b>104</b> has a second, larger, cut-out <b>108</b>. As shown, the cut-outs <b>106</b>, <b>108</b> are round; however, the cut-outs <b>106</b>, <b>108</b> are any desired shape such as a square or rectangle. Panels <b>100</b> and <b>102</b> are demarcated from one another by adjacent fold lines <b>110</b>. The fold lines <b>110</b> help allow the panels <b>100</b>, <b>102</b> to be folded over on to one another, as shown in <figref idref="DRAWINGS">FIG. 7</figref>. In addition, panels <b>102</b>, <b>104</b> are demarcated from one another by adjacent fold lines <b>112</b>. The fold lines <b>112</b> help allow the panels <b>102</b>, <b>104</b> to be folded over onto one another, as shown in <figref idref="DRAWINGS">FIG. 7</figref>. Panel <b>100</b> forms the base of the coaster <b>22</b>, panel <b>102</b> forms an intermediate layer of the coaster <b>22</b>, and panel <b>104</b> forms a top layer of the coaster <b>22</b>. The cut-out <b>106</b> for panel <b>102</b> is smaller than the cut-out <b>108</b> for panel <b>104</b>, and as such the coaster <b>22</b> has a tiered opening <b>113</b>. The coaster <b>22</b> also has notches <b>114</b> which, as shown in <figref idref="DRAWINGS">FIG. 7</figref>, are aligned with one another when the panels <b>100</b>, <b>102</b>, <b>104</b> are in the second configuration. Elastic bands <b>79</b> are placed around the coaster <b>22</b> through the notches <b>114</b> in order to help maintain the coaster <b>22</b> in the second configuration.

0045Convertible portion <b>50</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 3</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 8</figref>. In the second configuration, the convertible portion <b>50</b> forms a case <b>119</b> for holding storage media such as a CD or DVD <b>127</b>. The convertible portion <b>50</b> has two panels <b>120</b>, <b>122</b>, where panel <b>122</b> has a cut-out <b>124</b>. The cut-out <b>124</b> is sized to be slightly smaller than the storage media being held, for example a standard CD or DVD. The cut-out <b>124</b> is shown as a round cut-out. In other embodiments, the cut-out is other shapes such as a square or rectangle. The panels <b>120</b>, <b>122</b> are demarcated by adjacent fold lines <b>126</b>. Panel <b>120</b> and panel <b>122</b> are folded over on one another to form the case as shown in <figref idref="DRAWINGS">FIG. 8</figref>. In <figref idref="DRAWINGS">FIG. 8</figref>, a CD <b>127</b> (shown in phantom) is placed between the panels <b>120</b>, <b>122</b>. Because the cut-out <b>124</b> is smaller in size than the CD, a portion of the CD is viewed through the cut-out while securing the CD in the case <b>119</b>. Further, the case <b>119</b> has notches <b>128</b> and an elastic band <b>79</b> is optionally disposed around the case <b>119</b> through the notches <b>128</b>, helping to maintain the case <b>119</b> in the second configuration and helping to maintain the CD within the case <b>119</b>.

0046Convertible portion <b>51</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 3</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 9</figref>. In the second configuration, the convertible portion <b>51</b> forms a picture frame <b>24</b>. The picture frame <b>24</b> has three panels <b>130</b>, <b>132</b>, <b>134</b>, and each of the panels <b>130</b>, <b>132</b>, <b>134</b> has a display opening <b>136</b> formed therein. The panels <b>130</b>, <b>132</b> are demarcated from one another by adjacent fold lines <b>138</b>, and panels <b>132</b>, <b>134</b> are demarcated from one another by adjacent fold lines <b>140</b>. As shown in <figref idref="DRAWINGS">FIG. 3</figref>, the convertible portion <b>51</b> has ends <b>146</b>, <b>148</b>. Fold lines <b>138</b> and <b>140</b> are folded (e.g., about a 120 degree fold) to bring the ends <b>146</b>, <b>148</b> into contact, as shown in <figref idref="DRAWINGS">FIG. 9</figref>. The picture frame <b>24</b> also has notches <b>144</b>. The notches <b>144</b> are aligned with one another above and below the display openings <b>136</b>. Elastic bands <b>79</b> are placed around the picture frame <b>24</b>, helping to maintain the picture frame <b>24</b> in the second configuration. The picture frame <b>24</b> also has tabs <b>142</b> for holding a picture or other display item inside the display openings <b>136</b>.

0047Convertible portion <b>52</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 3</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 10</figref>. In the second configuration, the convertible portion <b>52</b> forms a rack <b>149</b>, for example a CD rack. The convertible portion <b>52</b> has a base panel <b>150</b> and an upper panel <b>152</b>. Adjacent fold lines <b>154</b> demarcate the base panel <b>150</b> from the upper panel <b>152</b>. The upper panel <b>152</b> is demarcated into two sub-panels by a fold line <b>156</b> (as shown in <figref idref="DRAWINGS">FIG. 3</figref>), which helps allow the upper panel <b>152</b> to be folded into a raised configuration, as shown in <figref idref="DRAWINGS">FIG. 10</figref>. The upper panel <b>152</b> also has one or more slots <b>158</b> to receive a case for storage media, for example the case <b>119</b> described above. An elastic band <b>79</b> is also optionally placed around the rack <b>149</b> and through the notches <b>160</b> in order to help maintain the rack <b>149</b> in the second configuration. Also, in the second configuration the notch <b>162</b> and the tab <b>164</b> fit together in order to help ensure alignment of the upper and lower panels <b>150</b>, <b>152</b> of the rack <b>149</b>.

0048Convertible portion <b>53</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 3</figref> and a second configuration where the convertible portion <b>53</b> forms a file divider. The convertible portion <b>53</b> has a panel <b>170</b> and a tab <b>171</b> formed on one side of the panel <b>170</b>. The convertible portion <b>53</b> is able to be removed from the protective insert <b>45</b> to form the file divider (the file divider is not shown separately). The tab <b>171</b> is a raised portion of the file divider on which an identifier is optionally placed for identifying groups of files.

0049Turning to <figref idref="DRAWINGS">FIG. 4</figref>, protective insert <b>46</b> has convertible portions <b>54</b>-<b>59</b>. These convertible portions <b>54</b>-<b>59</b> are each shown in a first configuration. As mentioned above, in the first configuration these convertible portions <b>54</b>-<b>59</b> are configured to protect the primary product <b>10</b> and/or reinforce a portion of a container or box. In the second configuration these convertible portions <b>54</b>-<b>59</b> form accessory products <b>22</b>, <b>24</b>, <b>26</b>, <b>28</b>, <b>60</b>, <b>119</b>, <b>149</b>, <b>219</b>, <b>229</b>.

0050Convertible portion <b>54</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 4</figref> and a second configuration (not shown in a separate figure) that forms a file folder. The convertible portion <b>55</b> has a first panel <b>180</b> and a second panel <b>182</b>. The panels <b>180</b>, <b>182</b> are demarcated from one another along adjacent fold lines <b>184</b>. The panels <b>180</b>, <b>182</b> are folded toward one another along the adjacent fold lines <b>184</b>, forming a file folder. The convertible portion <b>55</b> also has a tab <b>186</b>, which forms a raised portion that is used for identification of the contents of the file folder.

0051Convertible portion <b>55</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 4</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 11</figref>. In the second configuration, the convertible portion <b>55</b> forms the desk organizer <b>26</b>. The convertible portion <b>55</b> has a first bottom panel <b>190</b>, a top panel <b>192</b>, and a back panel <b>194</b>. The back panel <b>194</b> is demarcated from the bottom and top panels <b>190</b>, <b>192</b> by two sets of adjacent fold lines <b>196</b>. A bottom panel edge <b>198</b> and a top panel edge <b>200</b> are configured to mechanically fit together. As shown in <figref idref="DRAWINGS">FIG. 11</figref>, the convertible portion <b>55</b> is folded along fold lines <b>196</b> to bring the edges <b>198</b>, <b>200</b> into contact, placing the top panel <b>192</b> in a raised configuration with respect to the bottom panel <b>190</b>.

0052Tab <b>202</b> on the bottom panel edge <b>198</b> and notch <b>204</b> on the top panel edge <b>200</b> fit together, facilitating alignment between the top and bottom panels <b>190</b>, <b>192</b>. The convertible portion <b>55</b> also has a number of notches <b>206</b>. In the second configuration, the notches <b>206</b> are aligned, facilitating placement of an elastic band <b>79</b> around the desk organizer <b>26</b>, which helps maintain the desk organizer <b>26</b> in the second configuration. The top panel <b>192</b> has one or more holes <b>210</b> that are sized for holding a writing utensil such as a pen or a pencil, for example. The holes <b>210</b> are vertically aligned with holes <b>212</b> in the bottom panel <b>190</b>. A writing utensil is optionally disposed through the one or more holes <b>210</b>, and the tip of the writing utensil is disposed in a corresponding hole <b>212</b>, helping to allow the writing utensil to be held in an upright fashion. As shown in <figref idref="DRAWINGS">FIG. 4</figref>, the holes <b>212</b> in the bottom panel <b>190</b> are smaller than the holes <b>210</b> in the top panel <b>192</b>. The smaller holes <b>212</b> are configured to securely hold the smaller diameter of the tip of the writing utensil, while the larger holes <b>210</b> are configured to accommodate the larger diameter of the shaft of the writing utensil. Further, the desk organizer <b>26</b> also has a slot <b>208</b> formed in the top panel <b>192</b>. The slot <b>208</b> is shaped and configured for holding papers (e.g., business cards) or other items in an upright manner.

0053Convertible portion <b>56</b> has a first configuration shown in <figref idref="DRAWINGS">FIG. 4</figref> and a second configuration shown in <figref idref="DRAWINGS">FIG. 12</figref>. In the second configuration, the convertible portion <b>56</b> forms a cup holder <b>219</b>. The convertible portion <b>56</b> has a base panel <b>220</b> and four side panels <b>222</b>. The side panels <b>222</b> are demarcated from the base panel <b>220</b> by fold lines <b>224</b>. Each side panel <b>222</b> has two vertical sides <b>226</b>. When the side panels <b>222</b> are folded upward with respect to the base panel <b>220</b>, as shown in <figref idref="DRAWINGS">FIG. 12</figref>, the vertical sides <b>226</b> are adjacent, or in contact with, one another. Further, the side panels have notches <b>228</b>. The notches <b>228</b> are aligned with one another when the convertible portion <b>56</b> is in the second configuration. An elastic band <b>79</b> is optionally disposed around the cup holder <b>219</b> in order to help maintain the cup holder <b>219</b> in the second configuration. Also, the convertible portion <b>56</b> optionally has alignment notches and tabs (not shown) to help facilitate the alignment of the side panels <b>222</b>, as shown on convertible portion <b>48</b> in <figref idref="DRAWINGS">FIG. 3</figref>.

0054Convertible portion <b>57</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 4</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 13</figref>. In the second configuration, the convertible portion <b>57</b> forms a decorative pencil holder <b>229</b>. The convertible portion <b>57</b> has a first base panel <b>230</b>, four side panels <b>232</b> and a top panel <b>234</b>. The base panel <b>230</b> is demarcated from the side panels <b>232</b> along fold lines <b>236</b>. The side panels <b>232</b> each have two vertical edges <b>238</b> that are adjacent to, or in contact with, one another when side panels <b>232</b> are folded with respect to the base panel <b>230</b>, as shown in <figref idref="DRAWINGS">FIG. 13</figref>. The top panel <b>234</b> is demarcated from one of the side panels <b>232</b> along fold line <b>240</b>. The top panel <b>234</b> is folded in a direction that forms the closed box configuration shown in <figref idref="DRAWINGS">FIG. 13</figref>, bringing edges <b>242</b> and <b>244</b> adjacent to, or in contact with, one another. Further, each side of the decorative pencil holder <b>229</b> has holes <b>246</b> formed therein. Elongate instruments, such as writing utensils, are optionally placed in these holes <b>246</b> for storage. The convertible portion <b>57</b> also has notches <b>248</b>. As shown in <figref idref="DRAWINGS">FIG. 13</figref>, these notches <b>248</b> are aligned within one another in two groups and an elastic band <b>79</b> is placed around the decorative pencil holder <b>229</b> through each group of notches <b>248</b> in order to help maintain the decorative pencil holder <b>229</b> in the second configuration.

0055Convertible portion <b>58</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 4</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIG. 14</figref>. In the second configuration, the convertible portion <b>58</b> forms an inbox or outbox (which will be referred to simply as an “inbox <b>28</b>” for convenience). The convertible portion <b>58</b> has a base panel <b>250</b>, end panels <b>252</b>, and side panels <b>254</b>. In some embodiments, the base panel <b>250</b> is sized slightly larger than a standard 8.5 inch by 11 inch paper to accommodate papers being placed in the inbox. The end and side panels <b>252</b>, <b>254</b> are demarcated from the base panel <b>250</b> by fold lines <b>256</b>, <b>258</b>, respectively. The side and end panels <b>252</b>, <b>254</b> have vertical side edges <b>260</b>. In the second configuration, the side and end panels <b>252</b>, <b>254</b> are all folded in the same direction at about 90 degrees, and the vertical side edges <b>260</b> form the corners of the box, as shown in <figref idref="DRAWINGS">FIG. 14</figref>. The side and end panels <b>252</b>, <b>254</b> also have notches <b>262</b> on the vertical side edges <b>260</b>. These notches <b>262</b> are lined up with one another when the convertible portion <b>58</b> is in the second configuration, and an elastic band <b>79</b> is placed around the inbox <b>28</b>, helping to maintain the inbox <b>28</b> in the second configuration.

0056Convertible portion <b>59</b> has a first configuration as shown in <figref idref="DRAWINGS">FIG. 4</figref> and a second configuration as shown in <figref idref="DRAWINGS">FIGS. 15 and 16</figref>. In the second configuration, the convertible portion <b>59</b> forms a holder <b>279</b> for an electronic device, for example those sold under the tradename “IPOD” by APPLE, INC. The electronic device holder <b>279</b> has a front panel <b>280</b> with first and second cut-outs <b>282</b>, <b>284</b>. The first cut-out <b>282</b> is configured to view a screen of an electronic device, and the second cut-out <b>284</b> is configured to view and/or access a controller for the electronic device. As shown in <figref idref="DRAWINGS">FIG. 4</figref>, the first cut-out <b>282</b> is positioned above the second cut-out <b>284</b>. Further, the first cut-out <b>282</b> is rectangular and the second cut-out <b>284</b> is round, although these cut-outs are optionally any other suitable shape as desired.

0057The convertible portion <b>59</b> also has side panels <b>286</b>, back panels <b>288</b> and flaps <b>290</b>. The side panels <b>286</b> are demarcated from the front panel <b>280</b> by fold lines <b>292</b>. The side panels <b>286</b> are folded back, forming the sides of the electronic device holder <b>279</b>. The back panels <b>288</b> are demarcated from the side panels <b>286</b> by fold lines <b>294</b>. The back panels <b>288</b> are further folded back behind the front panel <b>280</b>, as shown in <figref idref="DRAWINGS">FIGS. 15 and 16</figref>. The flaps <b>290</b> are demarcated from the back panels <b>288</b> by fold lines <b>296</b>. The flaps <b>290</b> are folded in a direction away from the back of the electronic device holder <b>279</b>, as shown in the side profile of <figref idref="DRAWINGS">FIG. 15</figref>. The electronic device holder <b>279</b> is optionally rested on the flaps <b>290</b>, which holds the electronic device holder <b>279</b> in an upright position for easier viewing of the electronic device.

0058Further, the convertible portion <b>59</b> has a bottom panel <b>297</b> and a back overlay panel <b>298</b>. A slot <b>300</b> is formed in the back overlay panel <b>298</b> that is adapted to accommodate the flaps <b>290</b>. The bottom panel <b>297</b> is demarcated from the front panel <b>280</b> by fold line <b>302</b> and the bottom panel <b>297</b> is demarcated from the back overlay panel <b>298</b> by fold line <b>303</b>. The bottom panel <b>297</b> is folded backward along the fold line <b>302</b> to form the bottom of the electronic device holder <b>279</b>. The overlay panel <b>298</b> is further folded to the back of the electronic device holder <b>279</b> so that it overlays the back panels <b>288</b> and so that the flaps <b>290</b> extend through the slot <b>300</b>.

0059The convertible portion <b>59</b> also has a top panel <b>304</b> and a front panel overlay <b>305</b>. The top panel <b>304</b> is demarcated from the back panel overlay <b>298</b> by fold line <b>306</b>. The top panel <b>304</b> is folded forward along the fold line <b>306</b> over the top of the electronic device holder <b>279</b>, forming the top of the electronic device holder <b>279</b>. The front panel overlay <b>305</b> is demarcated from the top panel <b>304</b> by fold line <b>307</b>. The front panel overlay <b>305</b> is folded down over a portion <b>308</b> of the front panel <b>280</b>, as shown in <figref idref="DRAWINGS">FIG. 16</figref>. Notches <b>310</b> are also formed around the top portion of the electronic device holder <b>279</b>. An elastic band <b>79</b> is optionally disposed around the electronic device holder <b>279</b> to help maintain the electronic device holder <b>279</b> in the second configuration.

0060While <figref idref="DRAWINGS">FIGS. 1 and 2</figref> show a desk as the primary product <b>10</b>, in some embodiments other primary products <b>10</b> are shipped in packaging assemblies with convertible portions. For example, in some embodiments the primary product is a shelf or book case (not shown) that is packaged in a packaging assembly. The packaging assembly has a convertible portion with first and second configurations, similar to any of the packaging assemblies described herein. In the first configuration, the convertible portion is configured as a part of the packaging assembly. In the second configuration, the convertible portion is configured as an accessory product for the shelf or book case. In some embodiments, the packaging assembly has one or more convertible portions that form a picture frame in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIG. 9</figref>), one or more convertible portions that form a CD or DVD storage case in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIG. 8</figref>), one or more convertible portions that form a coaster in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIG. 7</figref>), one or more convertible portions that form a pencil holder in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIG. 6</figref>), or one or more convertible portions that form a rack in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIG. 10</figref>), or any other suitable convertible portions, or any combination thereof.

0061In other embodiments, the primary product is a chair (not shown) that is packaged in a packaging assembly. The packaging assembly has convertible portions with first and second configurations, similar to any of the packaging assemblies described herein. In the first configuration, the convertible portion is configured as a part of the packaging assembly. In the second configuration, the convertible portion is configured as an accessory product for the chair. In some embodiments, the packaging assembly has one or more convertible portions that form a coaster in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIG. 7</figref>), one or more convertible portions that form a pencil holder in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIG. 6</figref>), or one or more convertible portions that form an electronic device holder in a second configuration (e.g., as shown in <figref idref="DRAWINGS">FIGS. 15 and 16</figref>), or any other suitable convertible portions, or any combination thereof.

0062In yet other embodiments, the primary product is an ottoman, a footrest, an end table, or any other article of furniture. The article of furniture is packaged in a packaging assembly. The packaging assembly has convertible portions that have first configurations and second configurations as described herein. In the first configuration, the convertible portion is configured as a part of the packaging assembly. In the second configuration, the convertible portion is configured as an accessory product for the article of furniture.

0063In addition, as shown in <figref idref="DRAWINGS">FIG. 17</figref>, in some embodiments, a picture frame <b>500</b> has a frame <b>502</b> that forms a display opening. During shipment and/or display at a retailer, the frame <b>502</b> has a packaging material <b>504</b> disposed in the frame. The packaging material <b>504</b> has an edge portion <b>506</b> and a central portion <b>508</b>. The central portion <b>508</b> is demarcated from the edge portion <b>506</b> by perforation line <b>510</b>. The perforation line <b>510</b> helps to facilitate the removal of the central portion <b>508</b> from the packaging material <b>504</b>. The remaining edge portion <b>506</b> is suitable for a matting for the picture frame. As such, the packaging material <b>504</b> has a first configuration for storage and/or shipment and a second configuration (with the central portion <b>508</b> removed) for use with the primary product (the frame).

0064A method of shipping a primary product includes the step of providing a packaging assembly, for example any of the packaging assemblies described herein. In some embodiments, the packaging assembly includes a container and also optionally includes a protective insert. The packaging assembly has a convertible portion (e.g., any of the convertible portions described herein), and the convertible portion has a first and a second configuration. In the first configuration, the convertible portion is configured as a part of the packaging assembly. In the second configuration, the convertible portion is configured as an accessory product for the primary product. The primary product is disposed in the container. The optional protective insert is disposed in the container between the primary product and a wall of the container and/or around or between portions of the primary product. The container is then closed and secured for shipment.

0065A method of assembling a primary product includes providing a packaged primary product. The packaged primary product is disposed in a packaging assembly, for example any of the packaging assemblies described herein. In some embodiments, the packaging assembly includes a container and also optionally includes a protective insert. The packaging assembly has a convertible portion (e.g., any of the convertible portions described herein), and the convertible portion has a first and a second configuration. In the first configuration, the convertible portion is configured as a part of the packaging assembly. In the second configuration, the convertible portion is configured as an accessory product for the primary product.

0066The packaging assembly is opened and the primary product is removed from the package. The optional protective inserts are also removed from the packaging assembly. In some embodiments, the convertible portions are separated from the non-convertible portions of the packaging assembly, for example by separating the convertible portion from the non-convertible portions along one or more perforated lines. The convertible portion is altered from a first configuration to a second configuration by folding or otherwise manipulating the convertible portion. In some embodiments, as described above, the convertible portion has fold lines, and the convertible portion is folded along these fold lines. In the second configuration, the convertible portions are configured as accessory products for the primary product. In addition, in some embodiments the convertible portions have notches. These notches are aligned, for example as described and shown above with respect to each convertible portion in <figref idref="DRAWINGS">FIGS. 3-16</figref>, and an elastic band is placed around a portion of the accessory product in order to help securely maintain the convertible portion in the second configuration.

0067Various modifications and additions can be made to the embodiments discussed without departing from the scope of the present invention. For example, while the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.